Assemble-in-place modular storage

ABSTRACT

An modular storage rack, display or cube system formed by snap together panels with alignment guides, which may also support wheels, shelves, drawers and doors. The system is assemble-in-place and may shipped and displayed for sale in a flat pack.

BACKGROUND OF THE INVENTION

[0001] 1. Field Of The Invention

[0002] This present invention relates to a novel pack-flat andassemble-in-place storage system. More specifically, to a snap-togethermethod and system of panels, with interlocking edges, from which avariety of self-supporting, storage units, racks, display centers andcabinets may be constructed.

[0003] 2. Related Prior Art

[0004] Modular storage systems are useful to allow a user to customize acomponent system to fit his or her particular needs. Panel type storagewhereby a similar side panels are connected via edge members are foundin U.S. Pat. No. 5,638,973 issued to Dewey et. al, and U.S. Pat. No.5,466,058 issued to Chan. In both Dewey and Chan the containers may bestacked by placing a tab-like projection on the bottom edge of one partinto a grove-like indentation in the top of another.

[0005] U.S. Pat. No. 5,888,114 issued to Slocum et. al., teaches a toyassembly or modular storage system which has a self-supporting edgeelement to it. The Slocum storage system is a series of similar panels,which form cubes via a slide together extruded mating edge with a catchrunning down the periphery of one edge and a latch running down theother side. The structural integrity of the Slocum system derives fromits slide together fittings. Once two panels are latched in theslide-together fashion, the panel edges can only be disassembled bysliding them apart. Slocum illustrates a plethora of configurations forthe slide-in catch and corresponding slide-in latch, all relying on anextruded latch and catch which teaches no alignment guides or stops tomaintain the plumb alignment of connected panels.

[0006] Slocum's slide together mating system is limited to theconnection of 4 panels which may form a very strong and rigid box withan open top and bottom. Slocum employees a system of trusses anddissimilar panels to form a type of back to the cubes.

[0007] A remaining challenge in the field of modular storage systems isto provide similar panels which can edge mate to form 5 and 6 sidedcubes. Slide-in latch and catch systems have inherent limitations inthis regard. The present invention overcomes such limitations bycreating a snap-in latch and catch panel attachment which may also beuseful in construction and modeling toys.

SUMMARY OF INVENTION

[0008] The present invention is a modular storage system constructed ofidentical square panels. Each square panel has a front and a back sideand four edges and four corners. On either side of each corner, viewedfrom a front or a back side is found a latch/catch pair. At eachadjacent corner is formed another latch/catch pair, the sequence oflatch to catch is alternating around each side and mirror on theopposite side. The catch is elongated and semi-rigid, having adequateelasticity, memory and lubricity to deform and snap-back into place uponinsertion or removal of the corresponding elongated latch. Accordingly,a pair of oppositely oriented panels are able to snap together at the anedge forming a right angle between the two panels, additionally panelsmay be added to form structures such as racks, carts, desks and cubes.Each catch may also provide a stop to prevent the latch from slidingwithin the elongated catch and becoming misaligned.—a very differentfeature, which is unworkable with an extruded latching edge whichattaches via slide-through engagement of the components, such as thatfound in Slocum U.S. Pat. No. 5,888,114. At the corner between eachadjacent pair of edges on each panel a buttress is formed. Two adjacentcorners buttresses (FIG. 1D) support each other and act as a largercorner support which further stabilizes the structures constructed fromthe panels (FIG. 4 & 5A).

[0009] Although the preferred embodiment indicates the latch and catchedges are formed as part of each panel, affixing the latch and catchedges at the appropriate corner locations over a panel is alsocontemplated and set forth within. Advantages to affixing the latch andcatch edges include combining dissimilar materials which are impossibleor difficult to co-mold, such as a metal sheet, wood or metal grid panel(FIG. 8) affixed to plastic latches and catches. Doors and wheels (FIG.5) may also be added to a cube, panel or structure. The panels may haveprotruding or recessed surface features which may form a supportskeleton for a grid like panel (FIG. 2A, 114, 117 & 118) and may be usedto provide pathways or guides for shelves and/or drawers.

[0010] The features of the invention believed to be novel are set forthwith particularity in the appended claim. The invention itself, however,both as to configuration, and method of operation, and the advantagesthereof, may be best understood by reference to the followingdescriptions taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1A is a front perspective view of the preferred embodiment ofthe modular storage system.

[0012]FIG. 1B is a front view of an unattached corner of one panel ofthe preferred embodiment.

[0013]FIG. 1C is a rear view of an unattached corner of one panel of thepreferred embodiment.

[0014]FIG. 1D is a perspective view of an attached front corner of thepreferred embodiment.

[0015]FIG. 1E is a cut-away side view along line A-A of FIG. 1D.

[0016]FIG. 2A is a front perspective view of a first alternateembodiment of the modular storage system.

[0017]FIG. 2B is a front view of an unattached corner of one panel ofthe embodiment of FIG. 2A. FIG. 2C is a rear view of an unattachedcorner of one panel of the embodiment of FIG. 2A.

[0018]FIG. 2D is a blow-up of a front corner connection of theembodiment of FIG. 2A.

[0019]FIG. 2E is a cut-away side view along line A-A of FIG. 2C.

[0020]FIG. 2F is a cut-away edge view of the intersection of four cubes.

[0021]FIG. 3A is a front perspective view of a second alternateembodiment of the modular storage system.

[0022]FIG. 3B is a blown-up back perspective view of a, slide-on, cornerlatch/catch of the embodiment of FIG. 3A.

[0023]FIG. 3C is a blown-up front perspective view of a, slide-on,corner latch/catch of the embodiment of FIG. 3A.

[0024]FIG. 3D is a blow-up rear perspective view of a, slide-on, cornerlatch/catch of the embodiment of FIG. 3A.

[0025]FIG. 3E is a blow-up of a front corner connection of theembodiment of FIG. 3A.

[0026]FIG. 3F is a cut-away side view along line A-A of FIG. 3E.

[0027]FIG. 4 is a perspective view of one arrangement of the connectedpanels.

[0028]FIG. 5A is a perspective view of a second arrangement of theconnected panels.

[0029]FIG. 5B is a component view showing the door and attachment toFIG. 5A.

[0030]FIG. 5C is a component view showing the wheel and attachment toFIG. 5A

[0031]FIG. 6 is a perspective view of a third arrangement of theconnected panels.

[0032]FIG. 7 is a front view of a first alternate panel embodiment.

[0033]FIG. 8 is a front view of a second alternate panel embodiment.

BEST MODES FOR CARRYING OUT THE INVENTION

[0034] In the drawings, there is illustrated in FIG. 1A a frontperspective view of the preferred embodiment, generally designated 10.

[0035] The cube is formed of 5 identical substantially four sided panels11. Each panel has a front 12 and a back side 13 face and an edge 14 ateach side. At each end 15, of each edge 14, near the corners 16 of eachpanel 11, a latch/catch pair 20 is formed. Viewed from the edge 14, alatch 21 and a catch 22 are formed near the corner 16. The latch/catchpairs 20 are reversed such that on any given edge 15 of a panel 11 onelatch 21 will be exposed on one side and one catch 22 will be exposed onthe other side. This configuration allows identical, alternating panelsto be used to construct the entire structure.

[0036] Shown in FIGS. 1B, 1C, 1D and 1E, are front and rear perspectiveview of a corner of an unattached panel, a perspective view of anattached front corner and a cut away view of FIG. 1D at line A-A.

[0037] In FIGS. 1B & 1C the latches 21 shape is shown, the tabprojection forming the latch is elongated with an enlarged head 23 atits distal end which reversibly snaps into the corresponding elongatedcatch 22 slot 24. The panels are preferably an injection molded partconstructed out of acrylonitrile-butadiene-styrene “ABS”, Acetal, Acylicor Nylon. However, depending on the intended use, materials such aspolycarbonate, polypropylene or polyurethane may be substituted. Analignment stop 30 is formed at the junction of each edge 14. Thealignment stop 30 prohibits the type of movement common to latch/catchpanels which are connected via an extruded latch or catch which mounttogether via a slide in function. Additionally, as shown in FIG. 1D thealignment stops 30 form a buttress between panels enhancing thestructural integrity of the structure.

[0038] In FIG. 1E the enlarged head 23 forming the latch is shown matedfirmly within the slot 24 of the catch 22, by constructing the catch 22out of a material with sufficient lubricity, flexibility and memory theenlarged head 23 may be withdrawn, or snapped-out, of the slot 24, bydisplacing the slot walls 25 which will snap-back, undamaged, uponwithdrawal. A sufficiently flexible slot wall 25 also places less stresson the neck 26 of the latch 21 thereby minimizing the risk of neckdamage during attachment of panels.

[0039] Referring now to FIG. 2A there is illustrated a front perspectiveview of a first alternate embodiment of the modular storage system,generally designated 110.

[0040] The cube is formed of 5 identical, substantially square panels111. Each panel 111 is a square frame with a open grid structure formedtherein. Each panel has a front 112 and a back side 113 face and an edge114 at each side . At each end 115, of each edge 114, near the corners116 of each panel 111, a latch/catch pair 200 is formed. A panel grid117 is formed within the boundary of the edges 114 and a raised gridsupport 118 may be extended from the panel grid to provide greaterstability to the panel grid 117 and panel 111. Viewed from the edge 114,a latch 201 and a catch 202 are formed near the corner. The latch/catchpairs 200 are reversed such that on any given edge 114 of a panel 111one latch 201 will be exposed on one side and one catch 202 will beexposed on the other side. This configuration allows similar alternatingpanels, with corresponding latch/catch pairs 200 to be used to constructthe entire structure.

[0041] The nature of this invention is in the latch/catch pairs 200.Variations in the side panels are anticipated and discussed within. Sidepanels may be constructed in a wide variety of forms, with differentsurface features, cut-outs, skeletal structures, protrusions and thelike without departing form the intended scope of the invention.

[0042] Shown in FIGS. 2B, 2C, 2D and 2E, are a front and rearperspective view of a corner of an unattached panel, a perspective viewof an attached front corner , a cut away view of FIG. 2D at line A-A,and a cut-away edge view of the intersection of four cubes.

[0043] In FIGS. 2B & 2C the latch 201 shape is illustrated, the tabprojection forming the latch has a enlarged head 203 which snaps in areversible fashion into the corresponding catch 202 slot 204. The panelsare preferably an injection molded part constructed out ofpolypropylene, ABS, polycarbonate or nylon which provides flexibilityand durability. An alignment stop 230 is formed at the junction of eachedge 114. The alignment stop 230, adjacent to a corner buttress 235prohibits forward and back movement of a latch 201 within a catch 202.Additionally, the combination of two or more adjacent corner buttresses235 (FIG. 2D) forms a larger corner support further enhancing thestructural integrity of the structure.

[0044] In FIG. 2D the enlarged head 203 forming the latch is shown matedfirmly within the slot 204 forming the catch 202, by constructing thepanels out of a material with sufficient flexibility, memory andlubricity the enlarged head 203 may be withdrawn, or snapped-out, of theslot 204 without damaging the slot walls 205 or the neck 206 of thelatch 201. A support guide 250 is formed between the latch 201 and thecatch 202 , in FIG. 2E a support rod of a size and shape to mate withthe support guide 250 is shown. The support rod can be used to precludesnapping-off of the panels when such action needs to be restrict as maybe the case with young children or in commercial, school or businesslocations.

[0045]FIG. 3A shows a front perspective view of a second alternateembodiment of the modular storage system, generally designated 300.

[0046] The cube is formed of 5 identical, four sided panels 301. Eachpanel 301 is of a similar size. Each panel side has an edge 304. At eachend 305, of each edge 304, near the corners 306 of each panel 301, alatch/catch pair 320 is affixed. Viewed from the edge 304, a latch 321and a catch 322 are attached near the corner 306. The latch/catch pairs320 are reversed such that on any given edge 304 of a panel 301 onelatch 321 will be exposed on one side and one catch 322 will be exposedon the other side. This configuration allows alternating panels to beused to construct the entire structure.

[0047] In FIGS. 3B, 3C, 3C, 3E and 3F, there is shown a front, back andrear perspective view of the slide-on corner catch/latch, a perspectiveview of an attached front corner, a cut away view of FIG. 3E at lineA-A, and a cut-away edge view of the intersection of four cubes

[0048] In FIGS. 3B, 3C, and 3D the latch 321 shape is illustrated, thetab projection forming the latch is elongated and has a enlarged head323 which snaps in a reversible fashion into the corresponding catch 322slot 324. The latch/catch pairs 320 are preferably an injection moldedpart constructed out of polypropylene, ABS, polycarbonate, highdurometer rubber, or nylon which provides flexibility and durability. Analignment stop 330 is formed at the corner junction of each latch/catchpairs 320. FIG. 3E illustrates the position of the alignment stops 330which inhibits movement of a latch 321 within a catch 322 therebyenhancing the structural integrity of the structure. Surrounding eachcorner buttress 330 is a support edge 331 which engages an adjacentsupport edge 331 of a panel affixed adjacent and forms the larger cornersupport 332. A panel mating guide 340 is formed opposite eachlatch/catch pair 320. It is via this panel mating guide 340 that eachpanel 301 is fitted into the latch/catch pair 320. It is envisioned thateach panel 301 will be solidly affixed to the panel mating guide 340.The nature of the attachment will be dependent on the material the panelis constructed of, adhesives, locking tabs, sonic welds, glue, rivets,crimping and the like may be used.

[0049] The nature of this invention is in the latch/catch pairs 320.Variations in the side panels are anticipated and discussed within. Anon-exclusive list of possible side panel materials are framed wiremesh, coated wire, plastic grids, wood, metal, plastic, composites,sheet steel (stainless, hot or cold rolled carbon steel, or any alloy),brass, or copper stamped or formed, woven metal or plastic and metalframes inserted molded into plastic.

[0050] In FIG. 3F the enlarged head 323 forming the latch is shown matedfirmly within the slot 324 forming the catch 322, by constructing thelatch/catch pairs 320 out of a material with sufficient lubricity, theenlarged head 323 may be withdrawn, or snapped-out, of the slot 324without damaging the slot walls 325 or the neck 326 of the latch 321.

[0051] Shown in FIG. 4 there is illustrated a perspective view of onearrangement of the connected panels, generally designated 400.

[0052] A series of identical cubes 401 are attached together with onepanel 410 acting as a common panel shared between cubes 401. Alatch/catch pair (as described in FIGS. 1-3) is found on opposite sidesof each panel 410 to facilitate snap together construction of the cubes401.

[0053] Shown in FIGS. 5A, 5B and 5C there is a perspective view of asecond arrangement of the connected panels, generally designated 500forming a vertical storage case with wheels (FIG. 5C) and a swing door(FIG. 5B).

[0054] A series of identical cubes 501 are attached together (asdescribed in FIGS. 1-4) constructed out of identical panels 510 forminga tower. A shelf member 511 is held within a guide 512 formed as part ofthe surface feature of the panels 510.

[0055] A hinged door 520 attaches to one of the cubes 501 via a hingewhich has on latch 521 and one catch 522 (as described in FIGS. 1-3). Agroup of removable caster-type wheel modules 530 are affixed one perbottom corner, to the tower 500. Each wheel module 530 has one wheel 531and rod 532, which mates with a bose 533 formed in each corner of thebottom panel 510. Each rod 532 extends from a wheel stop 534 and mateswith the bose 533.

[0056] Shown in FIG. 6 there is a perspective view of a thirdarrangement of the connected panels, generally designated 600.

[0057] A series of identical cubes 601 are attached together (asdescribed in FIGS. 1-4) constructed out of identical panels 610 forminga tower. In the configuration the cubes 601 are of a scale for desktopuse to hold pads, paper, pens, clips, computer disks, CDs or other mediastorage devices. A series of rubber pads 620 may be affixed to thebottom surface of the lower cube 601 to inhibit slippage on a desktop.

[0058] Shown in FIGS. 7 & 8 there are front views of a first and secondalternate panel embodiments generally designated 700 & 800 respectively.

[0059] In FIG. 7 there is a metal and plastic panel which has a wireinsert 701 embedded within a preferably clear or translucent plasticstructure 702, within a four sided square frame 703. On opposite ends ofeach side of the square frame 703 a latch 704 and a catch 705 (aspreviously described in FIGS. 1-3) are affixed, or formed as a partthereof. On the back face (not shown) of the panel 700 opposite eachlatch 704 is a catch 705 and opposite each catch 705 is a latch 704.

[0060] In FIG. 8 a square four sided frame 801 supports a central mesh802 affixed at opposite ends of each side of the square frame 801 is alatch 803 and a catch 804 (as previously described in FIGS. 1-3). On theback face (not shown) of the panel 800 opposite each latch 803 is acatch 804 and opposite each catch 804 is a latch 803. The square frame801 and/or the mesh 802 may be constructed of plastic, metal or metalcoated with a rubber-like material , lacquered, painted or metal plated.

[0061] Since certain changes may be made in the above apparatus withoutdeparting from the scope of the invention herein involved, it isintended that all matter contained in the above description, as shown inthe accompanying drawing, shall be interpreted in an illustrative, andnot a limiting sense.

I claim:
 1. An assemble-in-place storage system comprising; a pluralityof substantially square panels each with four edges, four corners, afront side and a back side; eight alternating plastic latches andcatches formed near the corners on the front side of each panel, andadapted to engage corresponding catches and latches of a similar panel;and eight alternating plastic latches and catches formed near thecorners on the back side of each panel, and adapted to engagecorresponding catches and latches of a similar panel.
 2. The storagesystem of claim 1 wherein each latch and catch extends at approximatelya 45 degree angle from said front side or back side.
 3. The storagesystem of claim 1 wherein the panels are constructed from plastic andwindows are formed within the panels creating a panel grid appearance,whereby one may view the inside a cube formed by a group of panelsthrough a panel.
 4. The storage system of claim 1 wherein one or moreextended elongated guides may be formed on a panel whereby a shelf ordrawer may be supported.
 5. The storage system of claim 1 furthercomprising an alignment stop formed as part of each of said latches,whereby a corresponding catch engaged within the latch is inhibited frommoving side-to-side along the length of said catch.
 6. The storagesystem of claim 1 further comprising a corner buttress, with a supportedge, formed at the junction of a latch and catch on adjacent sides of acorner, whereby upon connection of any two or more panels, the supportedge of each adjacent corner buttresses contact each other and form alarger corner support.
 7. The storage system of claim 1 furthercomprising: a plurality of wheels each connected to a mounting post; awheel bose formed in each corners of a panel adapted to engage amounting post; and, a stop extending from each post whereby theinsertion of a post into a wheel bose is restricted.
 8. The storagesystem of claim 6 wherein each corner buttress is roughly a concavediamond shaped.
 9. The storage system of claim 1 further comprising: adoor; at least two hinges affixed on one side to said door and with afree end; and, at least one latch or catch extending from said free endadapted to engage with a corresponding latch and catch on said panel.10. The storage system of claim 1 wherein the panels are formed of aplastic-like material selected form the group consisting of,acrylonitrile-butadiene-styrene “ABS”, Acetal, Acylic, Nylon,polycarbonate, polypropylene, or polyurethane.
 11. The storage system ofclaim 3 further comprising a raised grid support formed along the saidpanel grid.
 12. An assemble-in-place storage system comprising; aplurality of substantially square panels each with four edges, fourcorners, a front side and a back side; a plastic latch and catch cornercover adapted to mount over the corners of each panel with alternatinglatches and catches supported thereon facing said either said front orsaid back side of said panels, and adapted to snap into a similar latchor catch of another panel; an alignment stop formed as part of each ofsaid latches, whereby a corresponding catch engaged within the latch isinhibited from moving side-to-side along the length of said catch; and acorner buttress, with a support edge, formed at the junction of a latchand catch on adjacent sides of a corner, whereby upon connection of anytwo or more panels, the support edge of each adjacent corner buttressescontact each other and form a larger corner support.
 13. The storagesystem of claim 12 wherein each latch and catch corner cover ispermanently affixed to said panel's corners.
 14. The storage system ofclaim 12 wherein the corner covers and panels are constructed ofdissimilar materials.
 15. An assemble-in-place storage systemcomprising; a plurality of substantially square plastic panels each withfour edges, four corners, a front side and a back side; eightalternating plastic latches and catches formed near the corners on thefront side of each panel, each extending approximately 45 degrees fromsaid front side, and formed with sufficient lubricity and memory to snapinto a latch or catch of another similar panel; eight alternatingplastic latches and catches formed near the corners on the back side ofeach panel, each extending approximately 45 degrees from said back side,and formed with sufficient lubricity and memory to snap into a latch orcatch of another similar panel; an alignment stop formed as part of eachof said latches, whereby a corresponding catch engaged within the latchis inhibited from moving side-to-side along the length of said catch;and a diamond corner buttress, with a support edge, formed at thejunction of a latch and catch on adjacent sides of a corner, wherebyupon connection of any two or more panels, the support edge of eachadjacent corner buttresses contact each other and form a larger cornersupport.
 16. The storage system of claim 15 wherein one or more extendedelongated guides may be formed on a panel whereby a shelf or drawer maybe supported.
 17. The storage system of claim 15 further comprising: aplurality of wheels each connected to a mounting post; a wheel boseformed in each corners of a panel adapted to engage a mounting post;and, a stop extending from each post whereby the insertion of a postinto a wheel bose is restricted.
 18. The storage system of claim 15further comprising: a door; at least two hinges affixed on one side tosaid door and with a free end; and, at least one latch or catchextending from said free end adapted to engage with a correspondinglatch and catch on said panel.
 19. A method of constructing anassemble-in-place storage system comprising the steps of; snapping thelatches and catches of a first side panel with alternating latches andcatches extending around its four corners, on both front and back sides,into the corresponding latches or catches of a similar second sidepanel; snapping the latches and catches of a third side panel withalternating latches and catches extending around its four corners, onboth front and back sides, into the corresponding latches or catches ofa similar second side panel opposite said first panel; and, snapping thelatches and catches of a fourth side panel with alternating latches andcatches extending around its four corners, on both front and back sides,into the corresponding latches or catches of said third and said firstpanels forming a cube open at the top and bottom.
 20. The method ofclaim 19 comprising the further step of snapping the latches and catchesof a bottom panel with alternating latches and catches extending aroundits four corners, on both front and back sides, into the correspondinglatches or catches of said first, second, third and fourth side panelsthereby forming a cube with a closed bottom.